Abrasion and corrosion resistant composite structural materials and the like

ABSTRACT

Structural materials, specifically rolls for use in steelfabricating processes, are disclosed for use in corrosive and erosive environments. In one arrangement the roll includes a base member or substrate to which is adhered a resin coating. A reinforcing mat or cloth is adhered to and partially embedded in the resin coating, before the latter hardens. A second resin layer is coated upon and partially impregnates the reinforcing mat. A second mat is then adhered to the second resin layer in a similar manner followed by a third coating of the resin material. A greater or lesser number of resin layers and reinforcing mats can be employed as required. The specific materials employed for the resin or plastic layers and the reinforcing cloths or mats can be varied according to the specific environment in which the roll will be used. For example, in presence of hydrofluoric acid the reinforcing mat may be Dynel cloth. For resilient contact with the work a suitable elastomeric layer is placed over the last resin or plastic coating.



2. The combination according to claim 1 characterized in that a coating of a primer material is applied to the last-mentioned one of said resin layers.
 3. The combination according to claim 1 characterized in that a laminated coating structure of alternating layers of said fiber glass and said resin materials is adhered to said core structure, and the outermost one of said layers is covered by a resin-impregnated mat layer, said mat being formed from at least one of the group consisting of fibrous crocidilite, asbestos, and polyvinyl chloride-acrylonitrile copolymer.
 4. In a roll for use in a corrosive environment, said roll including a core structure forming part thereof, a laminated covering on said core structure including layers of fiber glass material and said Mat, said mat being the outermost one of said layers, and corrosion-resistant coating means impregnating said fiber glass material and said mat and adhering said layers to one another and to said core structure.
 5. The combination according to claim 4 characterized in that a layer of corrosion-resistant resilient material covers said laminated structure.
 6. The combination according to claim 5 characterized further in that said resilient material is polychloroprene, and means are provided for adhering said polychloroprene to said coating means.
 7. The combination according to claim 6 characterized further in that said adhering means includes at least one coat of a primer material applied to said coating means and a coat of a cement material applied to said primer coat.
 8. A roll for use in a corrosive environment, said roll including a core structure forming part thereof, a layer of corrosion-resistant resin material adhered to said core structure, a layer of mat material formed from at least one of the group consisting of fibrous crocidilite, asbestos, and polyvinyl chloride-acrylonitrile copolymer adhered to said resin layer, a second layer of said resin material impregnating and covering said mat, and a layer of elastomeric material adhered to said second resin layer.
 9. A roll for use in a corrosive environment, said roll including a core structure forming part thereof, a layer of corrosion-resistant resin material adhered to said core structure, a layer of mat material formed from at least one of the group consisting of fibrous crocidilite, asbestos, and polyvinyl chloride-acrylonitrile copolymer adhered to said resin layer, a second layer of said resin material impregnating and covering said mat, and a coating of a primer material on said second layer of resin material.
 10. The combination according to claim 9 characterized adhered in that a coating of cement material is adhered to said primer coating, and a layer of acid-resistant polychloroprene is adhered to said cement coating.
 11. A composite abrasion and corrosion resistant structure comprising a base member, a reinforced polyester resin coating adhered to said base member, a reinforcing mat of fibrous material covering and partially embedded in said resin, said fibrous material being selected from the group consisting of polyvinyl chloride copolymer and fiber glass a second coating of said resin covering and partially impregnating said mat, and a layer of polychloroprene rubber adhered to said second coating.
 12. A composite abrasion and corrosion resistant structure comprising a base member, member including a relatively hard acid-resistant resin layer selected from the group consisting of polyester, phenolic and epoxy resins, a substantially coextensive mat of fibrous material adhered to and embedded in said layer selected from the group consisting of fiber glass and fibers of polyvinyl chloride copolymer, polyacrylonitrile, polyester, polyamide, asbestos, and crocidilite, and an errosion-resistant elastomeric material covering adhered to said resin layer.
 13. The combination according to claim 12 characterized in that said elastomeric material is selected from the group consisting of silicone, polyurethane, polychloroprene, chlorosulfonated polyethylene, butyl, ethylene-propylene-cyclopentadiene copolymer, butadiene, and natural rubbers.
 14. A composite abrasion and corrosion resistant structure comprising a base member, a reinforced plastic covering adhered to said base member, a reinforcing fibrous material embedded in said resin, said fibrous material consisting of polyacrylonitrile, and a layer of elastomeric material selected from the group consisting of butyl and chlorosulfonated polyethylene rubbers.
 15. A composite abrasion and corrosion resistant structure comprising a base member, reinforced polyester resin coatings adhered to said base member, a coextensive reinforcing fibrous mat embedded in an adjacent pair of said coatings, said fibrous mat being formed from a fiBrous material selected from the group consisting of polyvinyl chloride acrylonitrile copolymer and crocidilite, and a layer of elastomeric material selected from the group consisting of chlorosulfonated polyethylene and polychloroprene rubber adhered to the outermost one of said coatings.
 16. A roll for use in a corrosive environment, said roll including a core structure having a generally cylindrical work surface, a plastic coating adhered to said core structure including end portions thereof, a coextensive mat of fibrous material reinforcing said coating, and an elastomeric material covering adhered to that part of said plastic covering which covers said work surface.
 17. The combination according to claim 16 wherein a second plastic coating covers and partially impregnates said mat, a second lighter weight mat of fibrous material covers said second plastic coating, and a third plastic coating covers and impregnates said lighter weight mat.
 18. The combination according to claim 17 wherein a coextensive section of a cloth of fibrous material covers said third plastic coating, and a fourth plastic coating covers and impregnates said cloth.
 19. A composite abrasion and corrosion resistant structure comprising a base member, a number of plastic coatings selected from the group consisting of polyester, phenolic and epoxy resins and adhered to said base number, a substantially coextensive mat of fibrous reinforcing material selected from the group consisting of fiber glass and fibers of polyvinyl chloride copolymer, polyacrylonitrile, polyester, polyamide, asbestos, and crocidilite said mat being embedded in an adjacent pair of said coatings, and a layer of nitrile rubber adhered to the outermost one of said coatings.
 20. A composite abrasion and corrosion resistant structure comprising a base member, a plastic coating selected from the group consisting of polyester, phenolic and epoxy resins, a substantially coextensive mat of fibrous reinforcing material covering and partially embedded in said coating, said fibrous material being selected from the group consisting of fiber glass and fibers of polyvinyl chloride copolymer, polyacrylonitrile, polyester, polyamide, asbestos and crocidilite, a second plastic coating covering and partially impregnating said mat, and a layer of butadiene rubber adhered to said second coating.
 21. A composite abrasion and corrosion resistant structure comprising a base member, a plastic coating selected from the group consisting of polyester, phenolic and epoxy resins and adhered to said base member, said coating being reinforced with a substantially coextensive mat of fibrous material selected from the group consisting of fiberglass and fibers of polyvinyl chloride copolymer, polyacrylonitrile, polyester, polyamide, asbestos, and crocidilite said mat being adhered to and partially embedded in said coating, a second plastic coating covering and partially impregnating said mat, and a layer of natural rubber adhered to said second coating.
 22. A composite abrasion and corrosion resistant structure comprising a base member, said member including a relatively hard acid-resistant resin layer adhered to said base member, a coextensive reinforcing mat of fibrous material adhered to and embedded in said resin layer, a second resin layer bonded to said reinforcing mat and to said first-mentioned resin layer, and an erosion-resistant elastomeric material bonded to said second resin layer.
 23. The combination according to claim 22 characterized in that said base member is provided with a laminated structure of successive layers of said resin, and in that each of said layers has a reinforcing mat embedded therein.
 24. A steel mill roller, comprising a metal core, a rubber cover, and a protective layer of hard reinforced plastic interposed between said rubber cover and said metal core which is resistant to mineral acids and does not propagate cut or crack growth.
 25. A roller according to claim 24, wherein said protective layer is made up of fibrous glass reinforced polyester resin.
 26. A polyurethane rubber covered roll, comprising a metal roll core, a fiber layer impregnated with a thermosetting resin and wrapped on and united to the periphery of said core, and a polyurethane rubber layer encircling and united to said fiber layer. 